Duke Manufacturing FLEXIBLE BATCH BROILER Operation Manual
Installation & Operation Manual
FLEXIBLE BATCH BROILER
Duke Manufacturing Co.
2305 N. Broadway • St. Louis, Missouri
800-735-3853 • 314-231-1130 • Fax 314-231-5074
www.dukemfg.com
175500L
AS OF: 2/15/08
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INDEX
I. General Information ..........................................................................4
A. Batch Broiler Specifications................................................................................. 4
A-1.0 Model Number Key .................................................................................. 5
A-2.0 Broiler Dimensions ................................................................................... 5
II. Installation Instructions....................................................................6
A. Qualified Personnel ...........................................................................................6
B. Delivery and Inspection .....................................................................................7
C. Broiler Assembly................................................................................................ 8
D. Adjustments at Installation…………………………………………………………..9
E. Location of the Broiler........................................................................................ 10
F. Gas Piping ......................................................................................................... 10
G. Electrical Connections....................................................................................... 11
H Ventilation.......................................................................................................... 11
III. Operation Instructions.....................................................................12
A. Broiler Controls .................................................................................................. 12
B. Cooking Product ................................................................................................ 13
B-1.0 Lighting the Broiler ................................................................................... 13
B-2.0 Cook Product ........................................................................................... 13
B-3.0 Cook Cycle Complete .............................................................................. 14
B-4.0 Fine Cooking Adjustment......................................................................... 14
B-5.0 Cancel a Cook Cycle ............................................................................... 14
B-6.0 Checking the Broiler Temperature........................................................... 14
B-7.0 Checking the Set Point Temperature....................................................... 14
B-8.0 Shutdown the Broiler................................................................................ 14
C. Cleaning............................................................................................................. 15
C-1.0 Four (4) Hour Cleaning ........................................................................... 16
C-2.0 Daily Cleaning.......................................................................................... 17-19
C-3.0 Weekly Cleaning ...................................................................................... 19-22
C-4.0 Monthly Cleaning ..................................................................................... 23-24
D. Programming the Control ..................................................................................25
D-1.0 Entering Program Mode .......................................................................... 25
D-2.0 Navigating the Programming Screens..................................................... 25
D-3.0 Level 1 Programming............................................................................... 25
D-3.1 Product Identifier...................................................................................... 26
D-3.2 Cook Temperature................................................................................... 26
D-3.3 Cooking Profile ........................................................................................ 26
D-3.4 Exit Program Mode .................................................................................. 26
D-4.0 Level 2 Programming............................................................................... 26
D-4.1 F or C Parameter ..................................................................................... 26
D-4.2 Change the Idle Temperature.................................................................. 26
D-4.3 Additional Factory Parameters ................................................................ 26
D-4.4 Exit Program Mode .................................................................................. 26
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E. Troubleshooting ................................................................................................. 27-30
37
IV. Service and Repair ..........................................................................31
A-1.0 Warnings ........................................................................................................ 32
V. Replacement Parts List ...................................................................32-34
VI. Wiring diagram.................................................................................35
VII. Customer Assistance .....................................................................36
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THIS MANUAL MUST BE RETAINED FOR FUTURE REFERENCE.
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POST IN A PROMINENT LOCATION
to be followed in the event the user smells gas. This
information shall be obtained by consulting the local gas
Do not store or use gasoline or other flammable vapors or liquids in
FOR YOUR SAFETY:
the vicinity of this or any other appliance.
Improper installation, adjustment, alteration, service or
maintenance can cause property damage, injury or death. Read
the installation, operating and maintenance instructions
thoroughly before installing or servicing this equipment.
I. General Information
A. Batch Broiler Specifications
WARNING:
instructions
FLEXIBLE BATCH BROILER SPECIFICATIONS
ALTITUDE (MAXIMUM)
GAS PIPE CONNECTION
INLET PRESSURE RANGE
MANIFOLD PRESSURE MANIFOLD PRESSURE
INFRARED BURNERS (TOP)
LOWER BURNER
TOTAL ENERGY RATE
BURNER ORIFICE SIZE BURNER ORIFICE SIZE
FRONT INFRARED BURNER
BACK INFRARED BURNER
LOWER BURNER
NATURAL GAS PROPANE
2000 FT 607 m 2000 FT 607 m
3/4 “ F-NPT 3/4” F-NPT
7” – 12” W.C. 10” – 12” W.C.
3.75” W.C. 0.93 kPa 8.0” W.C. 2.0kPa
3.75” W.C. 0.93 kPa 8.” W.C. 2.0kPa
87000 – 111,000
BTU/HR
#40 2.49mm #52 1.61mm
#36 2.70mm #51 1.70mm
#31 2.05mm #49 1.85mm
25.5 – 32.5
kW
79,000 –
105,000 BTU/HR
23.2 – 30.7
kW
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A. Batch Broiler Specifications (cont’d)
SHIPPING WEIGHT: 482 lbs (219 Kg)
SHIPPING DIMENSIONS: 47” x 34” x 68” (119.4 x 86.4 x 172.7 cm)
MODEL NUMBER ELECTRIC NATURAL & LP GAS
FBB-NO-120 120VAC, 2A, 60Hz 87,000 – 111,000 BTU/HR
FBB-NC-120 120VAC, 2A, 60Hz 87,000 – 111,000 BTU/HR
FBB-PO-120 120VAC, 2A, 60Hz 79,000 – 105,000 BTU/HR
FBB-PC-120 120VAC, 2A, 60Hz 79,000 – 105,000 BTU/HR
A-1.0 Model Number Key
FBB-X Y -120
X = N (NATURAL GAS) OR P (PROPANE / LP GAS)
Y = O (NO CATALYST) OR C (CATALYST)
120 = 120 VOLTS
A-2.0 Broiler Dimensions
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II. Installation Instructions
A. Qualified Personnel
These installation instructions are for the use of
qualified installation and service personnel
only. Installation or service by other than
qualified personnel may result in damage to the
broiler and/or injury to the operator.
Qualified installation personnel are those
individuals, firms, companies or corporations
which either in person or through an agent is
engaged in and responsible for:
•The installation or replacement of gas piping
or the connection, installation, repair or
servicing of equipment, who are experienced
in such work, familiar with all precautions
required, and have complied with all
requirements of state and local authorities
having jurisdiction. See: National Fuel Gas
Code NFPA 54 (ANSI Z223.1).
•The installation of electrical wiring from the
electric meter, main control box or service
outlet to the electrical appliance. Qualified
installation personnel must be familiar with all
precautions required and have complied with
all requirements of state and local authorities
having jurisdiction. See: National Electrical
Code, ANSI/NFPA70.
For a broiler mounted on casters, the installation
shall be made with a connector that complies
with the Standard for Connectors for Movable
Gas Appliances, ANSI Z21.69/CSA 6.16 and a
quick-disconnect device that complies with the
Standard for Quick-Disconnect Devices for Use
with Gas Fuel, ANSI Z21.4/CSA 6.9. When
installing the broiler with casters and quickdisconnect hose, adequate means must be
provided to limit the movement of the broiler
without depending on the connector and the
quick disconnect device or its associated piping
to limit the broiler movement. A means for
restraining may be attached to the vertical
portion of the base frame in the rear of the
broiler.
The installation must conform with local codes, or
in the absence of local codes, with the National
Fuel Gas Code, ANSI Z223.1/NFPA 54, or the
Natural Gas and Propane Installation Code, CSA
B149.1 as applicable, including:
•The appliance and its individual shutoff
valve must be disconnected from the gas
supply piping system during any pressure
testing of that system at test pressures in
excess of ½ psi (3.5 kPa).
•The appliance must be isolated from the gas
supply piping system by closing its individual
manual shutoff valve during any pressure
testing of the gas supply piping system at test
pressures equal to or less than ½ psi (3.5
kPa).
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B. Delivery and Inspection
Duke Manufacturing Co. does everything within
its power to insure you received your broiler in
good condition. They are strapped down on
heavy wooden skids and packed to prevent
shipping damage. They have all been carefully
inspected before they were packaged and
consigned to the carrier.
Upon delivery of your Duke broiler:
• Look over the shipping container, carefully
noting any exterior damage on the
delivery receipt, which must also be
signed by the driver/ delivery person.
• Unpack and check for any damage, which
was not evident on the outside of the
shipping container.
• Check for concealed damage. The carrier
must be notified within fifteen (15) days of
the delivery of the broiler and the carton,
skid and all packaging materials must be
retained for inspection.
Duke Manufacturing Co. cannot assume liability
for loss or damage suffered in transit. The carrier
assumes full responsibility for delivery in good
order when the shipment was accepted.
However, we are prepared to assist you in filing
your claim.
Caution: The Broiler is very heavy!
Use adequate help for lifting.
1) Using a utility knife, cut away plastic wrap (Not
shown).
2) Remove Training Material Box
3) Remove the top cardboard and inner cap.
4) Remove cardboard from the corners (4 places).
5) Remove cardboard on the ends (2 places).
6) Remove banding straps (Cut with utility knife or
scissors: 5 places).
7) Remove box of attachable parts & accessories
from the front.
8) Safely lift one end of broiler and tap block towards
center and then sideways to remove. Repeat for
remaining blocks. This allows casters to touch
the pallet.
9) Remove the broiler from the shipping pallet using
3 people to guide and distribute it’s weight
(approx 335 lbs) accordingly. While carefully
supporting the broiler. Roll it forward until the
front casters are clear of the pallet. Lift the broiler
6-8 inches above and away from the pallet, and
gently place on floor to avoid damage to casters.
10) Remove protective blue tape from broiler panels,
double checking that no tape remains.
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loader mounting studs.)
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C. Broiler Assembly
Before assembling and installing the broiler,
please check to make sure that all necessary
parts are present.
Item # Part Name Part
Number
1 PRODUCT PAN SHELF 175353
2 DISCHARGE CHUTE 175340
3 DISCHARGE HOOD 175778
4 DISCHARGE PAN HOLDER 175358
5 DISCHARGE GREASE PAN 175357
6 “V” GREASE PAN 175325
7 MAIN GREASE PAN 175329
8 LOADER 175444
9 LOADER TRAY 175430
10 LOADER BRACKET 175438
11 DOOR 175429
12 LOADER RAMP 175741
13 IMPEDANCE PAN 175226
14 CATALYST (OPTIONAL) 175480
15 CATALYST GUARD (OPTIONAL) 175482
SANITATION PAIL
16
17 KIT, CLEANING TOOLS/INSTALLATION
TOOL CLEANING – LOWER BURNER
FLAME ROD TUBE CLEANER
BRUSH, TUBE CLEANER
TOOL-LOADER INSTALL
WRENCH, ALLEN, 3/16”
18 KIT – BROILER SVC. PARTS, NAT. GAS W/
CONTROLLER W/COOK CHAIN (OPTIONAL)
19 KIT – BROILER SVC. PARTS, PROPANE, W/
CONTROLLER W/COOK CHAIN (OPTIONAL)
20 KIT – USER REPLACEABLE, BOTTOM
BURNER, FLAME ARRESTOR, LOADER &
BURNER SHIELD (OPTIONAL)
21 KIT – USER REPLACEABLE, BOTTOM
BURNER & FLAME ARRESTOR (OPTIONAL)
22 KIT – GAS HOSE CONNECTOR ASSEMBLY
(OPTIONAL)
23 KIT – HIGH SUPPLY GAS PRESSURE
REGULATOR (OPTIONAL)
175842
175700
175725
175740
175726
175750
175690
175689
Setup
Install all items as shown below.
Loader Install Tool
(Included with Broiler Tools Kit)
Install loader bracket with (4) ¼-20 nuts.
Use supplied extension tool to remove and
reinstall nuts. (Nuts are shipped installed on
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D. Adjustments at Installation
Each broiler section and all its component parts
have been tested thoroughly and inspected
before your broiler was shipped from the factory.
However, it is sometimes necessary to further
test or adjust the broiler once it has been
installed. Such adjustments are the responsibility
of the Dealer or Installer. These types of
adjustments are not considered defects, rather a
normal and routine part of the proper installation
of the equipment.
These adjustments include but are not limited to:
• Adjustments to the gas pressure regulator
• Broiler height adjustment (if required)
No installation should be considered complete
without proper inspection and, if necessary, any
adjustments by qualified service or installation
personnel.
It is also important not to obstruct the natural flow
of combustion and ventilation air if the broiler is to
operate properly. This broiler should not be
installed on a curb base or sealed to the wall.
Either condition can restrict the flow of air to the
combustion compartment or prevent proper
ventilation of the unit. Before making any
connections to the broiler, check the ratings plate
to be sure the broiler specifications concur with
the type of gas and voltage to be supplied to the
broiler.
Raise or Lower Broiler
The broiler height can be adjusted via two
screws on each leg.
Caution: The Broiler is very heavy! Use
adequate help for lifting.
1. Lift one end of the broiler onto a wide,
sturdy stand (not supplied).
2. Remove (2) screws per leg and
raise/lower to threaded holes. Reinstall
screws.
3. Remove stand and safely raise/lower
broiler.
4. Place plastic hole plugs (supplied attach
to stand) in any unused holes.
Support broiler here
The rating plate is located on the back of the
control compartment cover panel on the right end
of the unit.
The plate bearing the broiler’s model number and
serial number is attached to the back side of the
unit.
Screw
Screw
Slide Leg.
Reinstall screws.
Plastic Hole
Plug
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E. Location of the Broiler
Proper planning and placement of the broiler will
give you the best results in terms of long-term
user convenience and satisfactory performance.
We urge you to give adequate thought in the
placement of your broiler prior to its arrival.
•The broiler should be placed in an area that
is free from drafts and accessible for proper
operation and servicing.
•The area around the broiler must be kept
clear of combustible materials. A minimum
clearance of:
Discharge End
Access Panel End
Rear
Floor/Table
Combustible
12" (305) 12” (305)
3" (76) 3” (76)
4" (102) 4” (102)
0" (0) 0” (0)
Non-
Combustible
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NOTE: Using the Loader Tray to support
heavy items or an individual’s body weight
can damage components of the broiler.
F. Gas Piping
The standard broiler consumes gas at a total of
100,000 BTU/hr. In order to achieve the degree
of performance for which the unit has been
designed, the overall piping plan of the kitchen,
properly sized, is essential. The installation of
this broiler must conform with all local codes, or
in the absence of any local codes, to the
National Fuel Gas Code, NFPA 54 and ANSI Z
223.1.
Your local gas supplier should consult the
National Fuel Gas Code for proper sizing and
installation of gas piping. Generally, piping should
be sized to provide a gas supply sufficient to
meet the maximum demand of all gas appliances
on a line without undue loss of pressure at the
outlet to the equipment. The total BTU
requirements of the equipment being served and
the length of the piping from the meter to the
appliances are major considerations in the proper
design of the gas supply system.
NOTICE TO INSTALLER:
THIS APPLIANCE SHALL BE CONNECTED
TO A GAS SUPPLY IN THE RANGE OF:
NATURAL GAS 7” TO 12” W.C.
PROPANE GAS 10” TO 12” W.C.
Gas supply pressure must be checked prior to
installation. If supply pressure is in excess of
12” W.C., The HIGH SUPPLY PRESSURE KIT,
Duke P/N 175689 shall be installed and
adjusted, per kit instructions, for an outlet
pressure of:
Natural Gas - 7” W.C.
Propane Gas – 11” W.C.
NOTE: A fixed restraint of the proper length
must be incorporated to secure the broiler to a
non-movable surface to eliminate strain on the
gas connector. If the broiler is removed from
its normal position, the restraint must then be
reattached when returned.
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G. Electrical Connections
Your broiler is supplied for connection to a
dedicated 120 volt, grounded circuit. The electric
motors, indicator lights and control circuits are
connected through a seven-foot electric supply
cord found at the rear of the broiler.
Before making any connections to these units,
check the rating plate to assure that the voltage
and phase of the broiler is compatible with the
electrical supply. When installing, all broilers must
be electrically grounded in accordance with local
codes, or in the absence of local codes, with the
National Electrical Code, ANSI/NFPA 70 (in
Canada - CSA Std. C22.2). Wiring diagrams are
located in the control compartment area of the
broiler. Standard wiring schematics are also
provided with this manual.
WARNING: This appliance is equipped with a
three-prong (grounding) plug for your
protection against shock hazard and should
be plugged directly into a properly grounded
three-prong receptacle. DO NOT cut or
otherwise remove the grounding prong from
this plug.
This inspection/maintenance should consist of,
but not be limited to:
• Inspection for blockages or build up
which might interfere with the venting of
the broiler.
• Repair of such blockages.
• Inspection of the venting canopy, its drive
motors and bells, etc.
Warning:
sheet pans, food containers or aluminum foil on
the top of the broiler. This will obstruct the
venting of cooking vapors and airflow through
the unit—resulting in poor cooking performance.
Do not place any objects such as
H. Ventilation
This appliance shall be installed with sufficient
ventilation to prevent the occurrence of
unacceptable concentrations of substances
harmful to health in the room in which the
appliance is installed.
Venting to a Canopy Exhaust Hood
A mechanically driven exhaust hood must have a
minimum capacity of 1700 m3/hr (1000 cfm) with
a minimum 100cm by 130cm (39.4 in by 51.2 in)
opening to adequately vent this appliance. The
specified capacity and opening is required in a
dedicated hood for this appliance or in addition to
other appliance vented through a common
canopy exhaust hood.
Maintenance of Ventilation System
The ventilation system must be maintained and
annually inspected by Qualified Personnel
concurrent as part of or in addition to
governmental requirements.
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III. Operation Instructions
The information in this section is intended for the
use of qualified operating personnel. Qualified
Operating Personnel are those individuals who
have carefully read the information contained in
this manual, are familiar with the function of the
broiler and/or have had experience with operating
the equipment described. We recommend
following these instructions to insure optimum
performance, long life and trouble-free service
from your broiler.
The controller is pre-programmed at the factory
for known recipes at the time of manufacture.
The product keys must be programmed with an
approved recipe and the broiler properly
calibrated prior to use.
A. Broiler Controls
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• 1. Power Switch – Turns the broiler ON or
OFF. The broiler is self-lighting.
• 2. Product Selection Keys – Selects the
product recipe to run. Also functions as
number keys 1-8 in programming mode.
• 3. Arrow Keys
Up-Arrow: Displays the current broiler
temperature when pressed in run mode.
Scrolls backward through parameters when
pressed in program mode.
Down-Arrow: Displays the broiler set-point
temperature when pressed in run mode.
Scrolls backward through parameters when
pressed in program mode.
Left-Right Arrows: Moves between
characters or parameters in program mode.
Also used as numerals 0 and 9 keys.
• 4. Display
• 5. Enter Key – Press and hold for 5
seconds to enter program mode. Also
used to move though and enter parameters
in programming mode.
4
3
2
5
1
• 6. Cook Light – This light is lit during
preheat and the entire cook. The operator
should not load the broiler while the light is
lit.
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